Methods for machine emulation and process response prediction

ABSTRACT

Methods for generating predicted product values of a product produced by a machine and for predicting a process of a machine are disclosed. A method for generating predicted product values of a product manufactured by a machine controlled by programmable logic control code includes presenting a machine input fields requesting parameters associated with actuators and mechanical elements, and presenting product input fields requesting desired product properties. The method further includes receiving parameters from the machine input fields, receiving desired product properties from the product input fields, and calculating output response data by an emulation of a mechanical operation of the machine using the parameters and the desired product properties. The output response data is provided to a product model that calculates predicted product values based on the output response data provided. The method further includes presenting the one or more predicted product values.

TECHNICAL FIELD

The present application relates generally to machine emulation as wellas product and process prediction. More particularly, the presentapplication relates to systems and methods for emulating a machine andpredicting product values of a product manufactured by a machine as wellas predicting a process of a machine having a plurality of actuators anda plurality of mechanical elements.

BACKGROUND

Machines and systems used to fabricate products, such as consumer goodsproducts, for example, often use programmable logic controllers tocontrol the various actuators of the machine. Programmable logiccontrollers are programmed with programmable logic controller code togenerate drive signals for the various actuators in accordance with adesired sequence to fabricate the products.

A designer or operator of the machine may be required to makemodifications to the programmable logic controller code for manyreasons. For example, there may be a change to the specifications to theproduct that necessitates a change to the programmable logic controllercode. A new product may require changes to the programmable logiccontroller code. Additionally, changes to the machine used to fabricatethe product may require updating the programmable logic controller code.

Modifying the programmable logic controller code may be time consumingfor the designer or operator. In many cases, changes are made to theprogrammable logic controller code is accomplished by trial and error.Changes are made and then observation of the machine with the codechanges is performed. However, such an iterative process may be timeconsuming and create down-time for the machine.

Accordingly, alternative systems and methods for emulation a machine,and predicting product values of a product manufactured by a machine aswell as predicting a process of a machine are desired.

SUMMARY

According to one embodiment, a method in a computer system forgenerating predicted product values of a product manufactured by amachine having a plurality of actuators and a plurality of mechanicalelements, the machine being controlled by programmable logic controlcode, includes presenting a plurality of machine input fields requestinga plurality of parameters associated with the plurality of actuators andthe plurality of mechanical elements, and presenting a plurality ofproduct input fields requesting a plurality of desired productproperties of the product. The method further includes receiving one ormore parameters from the plurality of machine input fields, receivingone or more desired product properties from the plurality of productinput fields, and calculating output response data by an emulation of amechanical operation of the machine using one or more parameters and theone or more desired product properties, wherein the emulation simulatesthe programmable logic control code. At least a portion of the outputresponse data is provided to a product model that calculates one or morepredicted product values based at least in part on the output responsedata provided to the product model. The method further includespresenting the one or more predicted product values.

According to another embodiment, a method in a computer system forpredicting a process of a machine having a plurality of actuators and aplurality of mechanical elements, the machine being controlled byprogrammable logic control code and configured to fabricate a productincludes presenting a plurality of machine input fields requesting aplurality of parameters associated with the plurality of actuators andthe plurality of mechanical elements, presenting a plurality of productinput fields requesting a plurality of desired product properties of theproduct, receiving one or more parameters from the plurality of machineinput fields, and receiving one or more desired product properties fromthe plurality of product input fields. The method further includescalculating, by a computer, output response data by an emulation of amechanical operation of the machine using one or more parameters and theone or more desired product properties, wherein the emulation simulatesthe programmable logic control code, and providing at least a portion ofthe output response data to a process model. The method also includesgenerating, by the process model, one or more process output messagesbased at least in part on the output response data provided to theprocess model, wherein the one or more process output messagescorrespond to a predicted process of the machine, and presenting the oneor more process output messages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a computer system for emulating a machineaccording to one or more embodiments illustrated and described herein;

FIG. 2 schematically depicts a human machine interface of a machineaccording to one or more embodiments illustrated and described herein;

FIG. 3 schematically depicts internal components of the computer systemdepicted in FIG. 1 or the human machine interface depicted in FIG. 2according to one or more embodiments illustrated and described herein;

FIG. 4 schematically depicts a graphical user interface of an emulatorcomputer program product for emulating a machine according to one ormore embodiments illustrated and described herein;

FIG. 5 schematically depicts a geometry settings form of a graphicaluser interface according to one or more embodiments illustrated anddescribed herein;

FIG. 6 depicts graphs and tables corresponding to output response datagenerated by a computer emulation of a machine according to one or moreembodiments illustrated and described herein;

FIGS. 7A and 7B depict a screen shot of a machine animation resultingfrom output response data according to one or more embodimentsillustrated and described herein;

FIG. 8 depicts a flowchart of the process for generating an animationfile of a machine animation according to one or more embodimentsillustrated and described herein;

FIG. 9 schematically depicts an emulator linked to a programmable logiccontroller of a machine according to one or more embodiments illustratedand described herein;

FIGS. 10A and 10B schematically depict a graphical user interface of anemulator computer program product for presenting training scenarios to auser according to one or more embodiments illustrated and describedherein; and

FIG. 11 schematically depicts a machine emulator computer programproduct linked to a product model and a process model according to oneor more embodiments illustrated and described herein;

FIG. 12 schematically depicts a diagram illustrating a machine emulatorlinked to a product model according to one or more embodimentsillustrated and described herein; and

FIG. 13 schematically depicts a diagram illustrating a machine emulatorlinked to a process model according to one or more embodimentsillustrated and described herein.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments disclosed herein are generally related to computer programproducts, systems, and methods for emulating a machine of amanufacturing process. Generally, the embodiments described herein maycomprise an emulator model that utilizes a calculation routine thatemulates programmable logic controller code used by a programmable logiccontroller provided as a component of the machine to control variousactuators of the machine. As used herein, the phrase “programmable logiccontroller” encompasses traditional programmable logic controllers aswell as microcontrollers, application specific integrated circuits(ASIC), and the like, that may be utilized in embedded systems. Further,the phrase “programmable logic controller code” as used herein meansprogram code that is executed by a programmable logic controller,microcontroller, ASIC, or the like. The calculation routine may usegeometric information regarding the various mechanical elements of themachine (e.g., mandrels, rods, turrets, etc.) and actuators (e.g., servomotors, pneumatic cylinders, hydraulic cylinders, linear actuators,etc.) to produce output response data, such as servo drive positioningtables, for example. In one embodiment, an animation of the machineprocess based upon user-inputted parameters is provided.

The embodiments described herein may be used by an operator of theemulated machine for training purposes. For example, the computerprogram product may be installed on a computer device that the operatormay use to enter various parameters to determine the effect of suchparameters without actually programming the programmable logiccontroller and perhaps causing damage to the products being manufacturedand/or the machine. Further, in one embodiment, training scenarios arepresented to the user that requests the user to make adjustments to theparameters in accordance with the training scenarios.

As described in detail below, embodiments may be used on a computerdevice as well as on the actual human machine interface of the machinebeing emulated. For example, an operator of a machine may switch betweenthe actual human machine interface used to control the machine and theemulator graphical user interface. The emulator model may be linked witha product model and/or a process model to share parameter valuestherebetween. Various embodiments of the computer program products,methods, and systems for emulating a process of a machine are describedin detail below.

Although embodiments are described herein in the context of a windermachine for winding a continuous web material onto rolls (e.g., papertowels), embodiments may be used to model any machine and/or process. Asnon-limiting examples, embodiments may be used to emulate a diapermanufacturing process, a shoe manufacturing process, and the like. Anexemplary winder machine for which the embodiments described herein mayemulate is described in U.S. Pat. No. 7,392,961. Embodiments describedherein may also be utilized in other industrial processes, such as theprocesses of spraying, gluing, and the manufacture of liquid/powderproducts, such as detergent. Although embodiments described hereinemulate mechanical elements and mechanical actuation, embodiments mayalso be used to emulate flow rates of fluid (e.g., based on nozzleconfiguration, fluid lines, etc.), fluid patterns and boundary layers,etc.

Referring now to the drawings, FIG. 1 depicts an exemplary computersystem 10 on which a computer program product in accordance with theembodiments described herein may be installed. The computer system 10may comprise a computer device 12, a graphics display device 13, andinput devices, such as a keyboard 14 and a mouse 15. It should beunderstood that while the computer system 10 is depicted as a personalcomputer system, this is a non-limiting example. More specifically, insome embodiments any type of computing device (e.g., smart phone, tabletcomputer, laptop computer, media player, server, specialized computer,etc.) may be utilized. As described in detail below, machine emulatorcomputer program code may be installed on the computer device 12 suchthat a user may input parameters into the graphical user interface toemulate machine processes.

Referring now to FIG. 2, an exemplary human machine interface 20 amachine is depicted, wherein the human machine interface 20 isconfigured as an operator terminal. An operator of a machine, such as awinder machine, may use the human machine interface unit to interactwith, program, and otherwise control the machine. The human machineinterface 20 of the illustrated embodiment comprises a machine graphicsdisplay device 23 and user input elements 24 (e.g., a keyboard and otherbuttons) built into a human machine interface cabinet 22. The humanmachine interface 20 may enclose a programmable logic controller 28 andother hardware components, such as a processor and memory (see FIG. 3).The human machine interface 20 may have a door 26 to provide access tothe electrical components maintained therein. The programmable logiccontroller may be electrically coupled to a plurality of actuatorsassociated with the machine, and may be programmed to provide outputsignals such that each of actuators move in accordance with programmablelogic controller code logic, which may be stored on a machine computerusable medium (i.e., a memory component) within the programmable logiccontroller. It should be understood that the human machine interface 20may take on a variety of configurations, and that embodiments of thepresent disclosure are not limited to the configuration of the humanmachine interface 20 depicted in FIG. 2. As an example and not alimitation, the human machine user interface may be configured as atablet or pendant that the operator may hold in his or her hands.

FIG. 3 depicts internal components of the computer device 12 or thehuman machine interface 20 depicted in FIGS. 1 and 2, respectively,further illustrating a system for emulating a process of a machine,and/or a non-transitory computer usable medium having a computer programproduct comprising computer readable code instructions for emulation ofa machine as hardware, software, and/or firmware, according toembodiments shown and described herein.

As also illustrated in FIG. 3, the computer device 12 or the humanmachine interface 20 may include a processor 30, input/output hardware32, network interface hardware 34, a data storage component 36 (whichmay store parameters data 38 a, output response data 38 b, and graphicselement data 38 c, described below), and a non-transitory memorycomponent 40. The memory component 40 and data storage component may beconfigured as volatile and/or nonvolatile computer readable medium and,as such, may include random access memory (including SRAM, DRAM, and/orother types of random access memory), flash memory, registers, magneticdisks, compact discs (CD), digital versatile discs (DVD), and/or othertypes of storage components. Additionally, the memory component 40 maybe configured to store operating logic 42, calculation routine logic 43,graphical representation logic 44, and animation logic 45 (each of whichmay be embodied as computer readable program code instructions,firmware, or hardware, as an example). A local interface 46 is alsoincluded in FIG. 3 and may be implemented as a bus or other interface tofacilitate communication among the components of the computer device 12or the human machine interface 20.

The processor 30 may include any processing component configured toreceive and execute computer readable code instructions (such as fromthe data storage component 36 and/or memory component 40). Theinput/output hardware 32 may be configured to receive signals from userinput and output devices such as a graphical display device, a keyboard,a mouse, a printer, a camera, a microphone, a speaker, a touch-screen,and/or other device for receiving, sending, and/or presenting data. Insome embodiments, the computer device 12 or the human machine interface20 may be connected to a network via the network interface hardware 34.The network interface hardware 34 may include any wired or wirelessnetworking hardware, such as a modem, LAN port, wireless fidelity(Wi-Fi) card, WiMax card, mobile communications hardware, and/or otherhardware for communicating with other networks and/or devices.

It should be understood that the data storage component 36 may residelocal to and/or remote from the computer device 12 or human machineinterface 20, and may be configured to store one or more pieces of data.As illustrated in FIG. 3, the data storage component 36 may storeparameters data 38 a, which in at least one embodiment includes aplurality of parameters entered into a graphical user interface by auser or an operator. The parameters may define operational andmechanical characteristics of mechanical elements and actuators of themachine. Similarly, output response data 38 b may be stored by the datastorage component 36 and may include output response data resulting fromprevious emulation sessions executed by the calculation routine logic43. Graphics element data 38 c used to generate animations of themachine process (e.g., computer graphics associated with each of theparts of the emulated machined, such as a mandrel, a belt, a turret,etc.) may also be stored in the data storage component 36.

Included in the memory component 40 may be the operating logic 42, thecalculation routine logic 43, the graphical representation logic 44, andthe animation logic 45. The operating logic 42 may include an operatingsystem and/or other software for managing components of the servercomputing device 12 b. The operating logic 42 may also include computerreadable program code for displaying the graphical user interfacedescribed herein. Similarly, the calculation routine logic 43 may residein the memory component 40 and may be configured to mimic theprogrammable logic controller code used to control the machine, andproduce corresponding output response data of the plurality ofmechanical elements and the plurality of actuators of the machine. Thegraphical representation logic 44 may be configured to receive theoutput response data generated by the calculation routine logic 43 andgenerate a graphical representation of output response data, such asgraphs and tables, for example. The animation logic 45 may be configuredto create one or more animations of a machine process based on theoutput response data generated by the calculation routine logic 43. Inan alternative embodiment, the memory component 40 and the data storagecomponent 36 are the same element such that the operating logic 42, thecalculation routine logic 43, the graphical representation logic 44, theanimation logic 45, the parameters data 38 a, the output response data38 b, and the graphics element data 38 c are all stored on the samephysical memory device.

It should be understood that the components illustrated in FIG. 3 aremerely exemplary and are not intended to limit the scope of thisdisclosure. More specifically, while the components in FIG. 3 areillustrated as residing within the computer device 12 or the humanmachine interface 20, this is a non-limiting example. In someembodiments, one or more of the components may reside external to thecomputer device 12 or the human machine interface 20.

As described above, embodiments of the present disclosure are directedto emulation of a machine and machine process using a graphical userinterface wherein the user may enter machine parameters into thegraphical user interface and the emulator module will produce outputresponse data corresponding with the parameters entered by the user. Asused herein, the phrase “graphical user interface” means any type ofinterface using a screen or monitor that presents information to a userand allows a user to input information. Graphical user interfaces mayinclude, but are not limited to, traditional graphical user interfaces(such as interactive windows), tables, and command line interfaces, suchas DOS prompts. Referring to FIG. 7A, a screen shot of an animation of ahybrid winder machine 210 provided by an emulation model of oneembodiment is illustrated. A winder or reel is typically known as adevice that performs the very first wind of the continuous web material,generally forming what is known as a parent roll. A rewinder, on theother hand, is generally known as a device that winds the continuous webmaterial from the parent roll into a roll that is essentially thefinished product. For purposes of the present application, the words“winder” and “rewinder” are interchangeable with one another.

As shown in FIG. 7A, a hybrid winder machine 210 of the exemplaryanimation generally comprises a winding turret 222 supporting aplurality of winding spindles 218 and a conveyor belt having a firstconveyor roller 228 and a second conveyor roller 230. The hybrid windermachine 210 may be suitable for use in winding a continuous web material212 to produce a final wound product 214. As an example and not alimitation, the continuous web material 212 may be transported by theconveyor belt 216 into winding contact with at least one winding spindle218. In one embodiment, a plurality of winding spindles 218 are disposedupon a winding turret 222 indexable about a center shaft therebydefining a winding turret axis. The winding turret 222 is preferablyindexable, or moveable, through an endless series of indexed positions.For example, a first winding spindle 224 can be located in what may beconveniently called an initial transfer position and a second windingspindle 226 can be located in what may conveniently be called a finalwind position. In any regard, the winding turret 222 may be indexablefrom a first index position into a second index position. Thus, thefirst winding spindle 224 may be moved from the initial transferposition into the final wind position. Such indexable movement of thefirst winding spindle 224 disposed upon winding turret 222 may comprisea plurality of discrete, defined positions or a continuous, non-discretesequence of positions. However, it should be appreciated that windingspindle 218 can be brought into proximate contact with conveyor belt 216by any means known to one of skill in the art.

In one embodiment, the conveyor belt 216 is driven at a surface speedthat corresponds to the speed of the incoming continuous web material212. A positioning device(s), such as first positioning actuator 252 andsecond positioning actuator 254 (e.g., linear actuators, servo motors,cams, links, and the like known by those of skill in the art), areprovided for control of the position of first conveyor roller 228 andsecond conveyor roller 230 supporting conveyor belt 216. Thus, firstpositioning actuator 552 associated with first conveyor roller 228 maybe capable of moving first conveyor roller 228 along a first axis. Insuch an embodiment, the first axis is generally parallel to theZ-direction relative to continuous web material 212 as web material 212passes proximate to a winding spindle 218. Likewise, second positioningactuator 254 associated with second conveyor roller 230 may be capableof adjusting the position of second conveyor roller 230 along a secondaxis. In such an embodiment, the second axis is generally parallel tothe Z-direction relative to web material 212 as web material 212 passesproximate to a winding spindle 218. The position of first conveyorroller 228 and second conveyor roller 230, when combined with the knowndiameter growth of the log associated with second winding spindle 226,can provide the desired contact, clearance, and/or pressure between theconveyor belt 216 and the log associated with second winding spindle226.

As mentioned above, the winding spindles 218 may engage a core (notshown) upon which the web material 212 is wound. The winding spindles218 are driven in a closed spindle path about the winding turret 222assembly central axis. Each winding spindle 218 extends along a windingspindle 218 axis generally parallel to the winding turret 222 assemblywinding turret axis, from a first winding spindle 218 end to a secondwinding spindle 218 end. The winding spindles 218 may be supported attheir first ends by the winding turret 222 assembly. The windingspindles 218 may be releasably supported at their second ends by amandrel cupping assembly (not shown).

Once the desired number of sheets of web material 212 has been woundinto a log associated with second winding spindle 226, a web separator234 can be moved into position proximate to web material 212 disposedupon conveyor belt 216 in order to provide separation of adjacent sheetsof perforated web material 212. The web separator 234 can be provided asa rotary unit sharing apparatus known to those of skill in the artuseful for the severance of the web material 212 into individual sheets.In one embodiment, the web separator 234 cooperates with the surface ofconveyor belt 216 upon which web material 212 is disposed. The webseparator 234 may be provided as a continuous speed roll movedintermittently and/or periodically into contact with the web material212 disposed upon conveyor belt 216. The movement of the web separator234 may be timed such that the web separator 234 nips the web material212 against the conveyor belt 216 when the perforation at the trailingend of the last desired sheet for the log associated with second windingspindle 226 is located between the first, or new, winding spindle 224 atthe transfer position (i.e., at the web material 212 nip point) and theweb separator 234 surface when it contacts the conveyor belt 216.Element 217 may be utilized to secure a loose tail of the web materialassociated with the second winding spindle 226 after the separation ofthe web material 212 by the web separator 234.

Referring now to FIG. 4, an exemplary graphical user interface 100 of anemulator computer program product for emulating a winder machine (i.e.,“emulator”) is illustrated. The graphical user interface 100 of theillustrated embodiment is for the winder machine that is schematicallyillustrated in FIG. 7A. As described above, the graphical user interface100 may be generated and displayed by the computer device 12 or thehuman machine interface 20 illustrated in FIGS. 1-3. In one embodiment,a visual layout of the graphical user interface 100 of the emulator issubstantially similar to the graphical user interface of the actualhuman machine interface 20 used to program and control the machine. Inthis manner, operators of the machine may feel comfortable operating theemulator, and real scenario training of operators may be facilitated.

Generally, the graphical user interface 100 of the emulator comprises aplurality of input fields 101-106 into which a user may enter orotherwise adjust parameters associated with mechanical elements andactuators of the machine, as well as product parameters desired of thefinished, wound product. As an example and not a limitation, theemulator may be a VB.Net 2010 application. Mechanical elements aredefined herein as the mechanical components of the machine, such asbelts, mandrels, turret, rods, etc., while actuators are defined hereinas the components that provide motion to the machine, and may include,without limitation, servo motors, linear actuators, pneumatic actuators,and hydraulic actuators. An individual input field displayed by thegraphical user interface 100 may correspond to a particular property ofa mechanical component or actuator of the machine (e.g., size, length oftravel, actuation speed, etc.). The input fields 101-106 displayed bythe graphical user interface 100 may be the same input fields displayedby the human machine interface of the machine.

As an example and not a limitation, plurality of machine input fields101-103 may correspond with hybrid winder machine element/actuatorparameters, while plurality of product input fields 104 may correspondwith various product parameters. The parameters associated with inputfields 101-103 may correspond, for example, to elements such as theconveyor belt 216, first and second positioning actuators 252, 254,winding turret 222, web separator 234, etc.

More or fewer input fields may be provided depending on the particularapplication. It should be understood that the type of parameters andinput fields will depend on the machine being emulated. For example, theparameters for a machine used to manufacture shoes will have differentmechanical elements and actuators than a winder machine and thereforethe graphical user interface face will display input fields.

In one embodiment, a user of the emulator may also define the geometricconfigurations of the various mechanical elements of the machine. As anexample and not a limitation, a user may select an option from a menubar 107 to display a geometry setting form such as the geometry settingsform 160 depicted in FIG. 5. The user may enter dimensional parametersinto the form into a plurality of input fields 164/165 of the geometrysettings form 160. In the illustrated example, the geometry settingsform 160 enables a user to enter parameters associated with a particularmachine element associated with geometry tab 162 d. Parameters for othermachine elements may be entered by selected geometry tabs 162 a-162 c.In one embodiment, the geometry settings form includes error checkinginput fields 164 and machine element geometry input fields 165. Theerror checking input fields 164 may allow a user to enter belt actuatorminimum and maximum parameters such that the emulator may generate errormessages when the output response data for the belt actuator indicatesthat the belt actuator is below the minimum or above the maximum valuesentered into the error checking input fields 164. Similarly, the usermay enter belt geometry parameters into the plurality of machine elementgeometry input fields 165 (e.g., machine element dimensions). Thegeometry settings form 160 may be used by the user (e.g., machinedesigner, operator, trainee, etc.) to make design changes to the machineto predict how the redesigned machine will perform without actuallychanging the physical machine.

Input fields 106 may correspond with parameters associated with theproduct. In the winder machine context, the product may be wound webmaterial, such that the parameters associated with input fields 106 maybe sheet length, roll diameter, etc.

The parameters inputted into the plurality of input fields 101-106 andthe geometry settings form 160 may be received and used by calculationroutine logic that mimics the actual programmable logic controller codeof the programmable logic controller in detail to produce outputresponse data such that the machine process is emulated. A user mayalter one or more parameters to predict an output response of themachine without physically running or altering the machine. Thecalculation routine may allow for ease of future updates to the machineand may reduce the potential for errors in the code.

The calculation routine logic may be computer readable program code thathas been translated from the programmable logic controller code andoperable to run on a computer device. As an example and not alimitation, the calculation routine logic may be implemented in anevent-driven programming language (e.g., Microsoft® Visual Basic, orsimilar languages) application. Programs of the programmable logiccontroller code may be translated into modules, and routines may betranslated into subroutines and functions, within calculation routinelogic of the emulator application. In some embodiments, othercalculation software packages may be used to develop functions that areimported into the calculation routine logic (e.g. MATLAB-generatedalgorithms provided as a DLL file utilized by the calculation routinelogic).

In one embodiment, the output response data produced by the calculationroutine may be displayed in a graphical representation within thegraphical user interface 100. The graphical representation of the outputresponse data may come in a variety of forms. In one embodiment, asdepicted in FIG. 4, the graphical representation may be in the form of aservo drive data chart 120 that displays servo drive data of one or moreof the servo actuators of the machine. In one embodiment, the servodrive data chart 120 mimics an output from the programmable logiccontroller code used to control the machine. The graphicalrepresentation may provide graphs (as well as tables) of the actuators'position, velocity, acceleration, and jerk. The graphical user interface100 may include a graphical representation selection area 130 having oneor more selectable buttons to generate particular charts, graphs,tables, etc. In the illustrated embodiment, the graphical representationselection area 130 has an upper belt button to generate an upper beltchart, a lower belt button to generate a lower belt chart, a chopperroll button to generate a chopper roll chart, a tail pan button togenerate a tail pan chart, a roll build button to generate a roll buildchart, a turret button to generated a turret chart, and a mandrel buttonto generate a mandrel chart. By selecting one of these buttons withinthe graphical representation selection area 130, a user may cause agraph and/or table depicting output response data associated with theparticular actuator (e.g., the upper belt, the lower belt, etc.).

FIG. 6 depicts exemplary graphs and tables of output response data 175generated by the emulator with respect to the upper belt actuator. Morespecifically, FIG. 6 depicts four graphs 176 and four tables 177relating to output response data 175 in machine degrees for a particularmechanical element or actuator. As an example and not a limitation, thegraphs 176 and tables 177 may correspond to element position, elementvelocity, element acceleration, and element jerk. The element may be anymachine element or actuator (e.g., a machine belt). In one embodiment,the user may zoom or pan the graphs using an input device (e.g., a mouseor a touch screen). Further, in some embodiments the output responsedata 175 generated by the calculation routine may be exported to aspreadsheet for further analysis.

Referring once again to FIG. 4, the graphical user interface 100 mayinclude one or more animation buttons 122, 124 that cause an animationof at least one predicted machine operation to be displayed. In theillustrated embodiment, the graphical user interface 100 includes a“View Single Animation” button 122 and a “View Comparison Animation”button 124. Selection of the “View Single Animation” button 122 maycause an animation of a machine process corresponding output responsedata resulting from an emulation using the currently inputtedparameters. FIG. 7A depicts a screen shot of an animation of a windermachine process. The animation may depict the movement of the mechanicalelements of the machine over a range of machine degrees (e.g., 0 to 360degrees). The animation may be based on the output response dataproduced by the calculation routine, and graphics elements associatedwith each of the mechanical elements and actuators. A graphics elementprovides a graphical representation of a mechanical element or anactuator within the animation. As an example and not a limitation, theanimation may be an Adobe Flash-based executable file that providescontinuous single-cycle animation. Other file formats may also beutilized. The animation may provide a visual indication to a user ofchanges made to the parameters inputted into the graphical userinterface 100. A user may stop or start the animation by selecting theplay/pause button 262, jump to a particular point in time of theanimation using the scroll bar 260, change the speed using speed scrollbar 264, select a modeling mode using model mode selection 269 (e.g.,select between a three-dimensionally rendered animation or atwo-dimensionally rendered line animation, or select between one or moreanimations), and zoom in and out using zoom buttons 268. Other featuresmay also be provided.

Selection of the “View Comparison Animation” button 124 may allow a userto select two (or more in some embodiments) previously saved filesrepresenting two different output response data sets for a comparisonanimation wherein two animations are overlaid with respect to oneanother. FIG. 7B depicts a screen shot of a comparison animation of twoanimations corresponding to two different output response data sets(e.g., a first machine animation 700 generated from a first plurality ofparameters and a second machine animation 710 generated from a secondplurality of parameters). For example, the output response data for thefirst machine animation 700 may have resulted from a first set ofparameters, while the output response data for the second machineanimation 710 may have resulted from a second set of parameters that isdifferent from the first set of parameters. A user may then visualizethe differences between the two animated machine processes and makeadjustments to the parameters accordingly.

The animation file may be created in a variety of ways. FIG. 8 depicts aflowchart 270 of a process to create a Flash-based animation file. Atblock 272, the calculation routine logic 43 receives a plurality ofparameters entered into the graphical user interface 100 as describedabove. Using the plurality of parameters, a calculation routine isexecuted to emulate the machine process and produce output response dataat block 274. In response to a request for the display of one or moreanimation files, multiple comma-separated values files are generated atblock 276. One comma-separated values file may list the geometryparameters entered into the geometry settings form 160 (i.e., a geometrysettings comma-separated values file). Another comma-separated valuesfile may list the output response data generated by the calculationroutine in the form of position vs. time output data from one or moreactuators (i.e., an output response comma-separated values file). Aflash executable file pre-built with graphics elements that representmachine elements (i.e., cylinders, rods, etc.) may then be started andload the data from the comma-separated values files to display acontinuous single cycle animation in block 278. In the comparisonanimation, an A set and a B set of comma-separated values files may becreated that a Comparison Flash executable file loads into arrays anddisplays an overlaid output.

In an alternative embodiment, the emulator may generate and presentstill images representing the output response data based on differentpoints in the emulated process rather than, or in addition to, ananimation of the output response data. In this embodiment, a user mayselectively view still images of the emulated process at desired pointsor times during the process. For example, the screen shots of theanimations depicted in FIGS. 7A and 7B may be configured as still imagesrather than animations as described above.

In one embodiment, the emulator is configured to calculate and outputprogrammable logic controller input values based on the parametersinputted into the graphical user interface 100 that may then be inputtedinto the programmable logic controller. For example, the emulator mayproduce a report that lists the programmable logic controller inputvalues for each actuator based on the parameters that the user hasentered into the graphical user interface 100. In this manner, aprogrammer or designer may easily enter the programmable logiccontroller input values generated by the emulator into the programmablelogic controller. The emulator may also be configured to receiveparameters inputted into the human machine interface from theprogrammable logic controller 28. For example, the graphical userinterface 100 may be displayed within the human machine interface (e.g.,the human machine interface 20 depicted in FIG. 2) so that a user mayview an animation based on parameters or values entered into theprogrammable logic controller 28. In this manner, the operator of themachine may view not only the actual operation of the machine based onthe parameters or values entered into the human machine interface, butalso a detailed animation that may provide information that may not bereadily apparent to the operator based on observing the machine alone.

Further, in another embodiment, the emulator may receive the actualoutput data of the programmable logic controller 28 (e.g., servo drivedata) separate from, or in addition to, the parameters or values enteredinto the programmable logic controller 28 via the human machineinterface. In this embodiment, the animation file is based on the actualoutput data (e.g., servo drive data or other drive data)of theprogrammable logic controller 28 rather than the output response datagenerated by the emulator. Therefore, the operator of the machine mayview an animation that is based on the actual output data of theprogrammable logic controller 28.

FIG. 9 illustrates an embodiment wherein the emulator 50 iscommunicatively coupled to the programmable logic controller 28, whichhas machine computer readable medium 27 that store programmable logiccontroller code. As an example and not a limitation, the emulator 50 maybe installed within the human machine interface 20 as depicted in FIG.2. In this embodiment, a user of the emulator 50 may enter variousparameters into the graphical user interface 100 displayed by theemulator and then output programmable logic controller values directlyinto the programmable logic controller 28. The programmable logiccontroller 28 may then send output signals to the various actuators 29a-29 d. Communication between the emulator 50 and the programmable logiccontroller 28 may be effectuated by a variety of means. For example acommercially available object linking and embedding for process control(OPC) software package or dynamic data exchange (DDE) software packagemay be used to enable communication between the emulator 50 and theprogrammable logic controller 28. It should be understood that othermethods of communication may be utilized, such a custom driver writtenfor communication between the emulator 50 and the programmable logiccontroller 28, for example.

The emulator and its graphical user interface may also incorporate smarttesting such that the emulator may be used as a training tool to trainnew operators of the machine. FIG. 10A depicts a graphical userinterface 100 that displays a training scenario to the user via a pop-uptraining scenario message box 150. It should be understood that thetraining scenario may be presented in a manner other than a message box.The training scenario message box 150 may include text that describes aparticular situation relating to the machine and prompts the user tomake the appropriate parameter change(s) by inputting the correctparameter(s) into the correct corresponding input field(s). A feedbackmessage (e.g., in a feedback message box) may be presented to the userin response to the inputted parameters. For example, the feedbackmessage may indicate that the user entered to correct parameters, or thefeedback message may indicate to the user that he or she is incorrect,and also indicate the correct parameters that the user should haveentered in response to the training scenario. In this manner, theemulator may provide real-time feedback based upon the changes made bythe user.

FIG. 10B illustrates a video training scenario message box 152 thatincludes a video display of an exemplary mechanical process of themachine that presents a question referring to a problem or issue.Similar to the training scenario message box 150 depicted in FIG. 10A,the video training scenario message box 152 prompts the user to makeparameter changes, and will then provide feedback to the user based onhis or her response. In this manner, the machine may be emulated whilealso displaying real-time feedback to the user.

In some embodiments, if a user does not answer a particular questioncorrectly (either a text-based question or a video question), theemulator may be configured to ask the same question again at a latertime during the same or a different training scenario, or it may beconfigured to ask the question in a different manner. As an example andnot a limitation, the emulator may be configured to ask a user a textbased question that corresponds to a video question that the useranswered incorrectly.

FIG. 11 illustrates a system 300 wherein the machine emulator (e.g.,emulator module 340) is also communicatively coupled to a product model320 corresponding to the product manufactured by the machine and aprocess model 330 of the overall process used to manufacture theproduct. The emulator module 340 may be communicatively coupled to onlythe product model 320, only the process model 330, or both.

Linking the emulator module 340 to the product model 320 may allow theuser to input product parameters as required by the product model andthen, based upon the inputted process/equipment settings, the productimplications could be displayed to the user within the graphical userinterface. Similarly, linking the emulator module 340 to the processmodel 330 may allow the user to input product parameters as required bythe process model and then based upon the inputted process/equipmentsettings, the process implications could be displayed to the user. Likethe emulator module 340, the product model 320 and the process model 330may be configured as computer readable program code, such as productmodel computer readable program code and process model computer readableprogram code, respectively. The emulator module 340, the product model320 and the process model 330 may all be stored in a single memorycomponent (i.e., a computer readable medium capable of storing computerreadable instructions that are executable by a processor) of a singlecomputer device (e.g., a personal computer, a server, the human machineinterface, etc.). In another embodiment, the emulator module 340, theproduct model 320 and the process model 330 may be stored on separatedmemory components of separate computer devices.

Referring now to FIG. 12, a system in which an emulator module 340 islinked to a product model 320 is illustrated. The product model may beconfigured as a mathematical model of a product that is generated incalculation software, such as, but not limited to, MathCAD, MATLAB,Excel, and the like. The product model 320 (e.g., a MathCAD model or aMATLAB model) may be configured to receive input parameters andcalculate predicted product values 322 (i.e., transform input parametersinto predicted product values). The product model 320 may be linked tothe emulator module 340 such that the product model 320 receivesinputted parameters from the emulator module 340 rather than from a user(although the product model 320 may be configured to receive inputtedparameters from both the emulator module 340, a user, and othersources). In one embodiment, various desired product properties 342(e.g., parameters corresponding to input fields 101-106 illustrated inFIG. 4) may be entered into the emulator module 340, as described above.The desired product properties may reflect desired characteristics ofthe finished product. Although the desired product properties 342 areshown as broken out into product properties 344 (e.g., sheet count,sheet length, etc.) and material properties 346 inputted into one ormore material input fields of the graphical user interface (e.g., papercaliper, stretchability, etc.) embodiments are not limited thereto. Forexample, the machine process properties described above may also beinputted as the desired product properties. Any parameter describedabove with respect to the finished product and the overall process maybe inputted.

After receiving the desired product properties 342, the emulator module340 may calculate output response data, as described above. The outputresponse data may include input parameters that are then provided to theproduct model 320. In one embodiment, some or all of the desired productproperties 342 are also provided to the product model 320. The productmodel 320 may then utilize the provided input parameters from theemulator module 340 to calculate and output various predicted productvalues. In a wound web material product context, such as a paper towelroll, the various predicted product values 322 may include, but are notlimited to, roll diameter value, perforation strength value, windingtension value, roll compressibility value, embossed depth value, etc. Inthis manner, a user may make changes to the desired product propertiesof the product and/or the process of the machine (e.g., actuatorparameters, geometry parameters, etc.) using the emulator, and thenpredict various output properties of the finished product.

In one embodiment, the emulator module 340 may provide an option thatgenerates a graphical representation of an anticipated product at anypoint during the process based on the parameters entered into theemulator module 340 and the parameters of the product model 330 (as wellas the process model 330). The graphical representation of theanticipated product may include, but is not limited to, athree-dimensional illustration, a pictorial representation, or a CADfile. The graphical representation of the anticipated product may allowthe user to see how the resulting product will look. For example, theemulator module 340 may be configured to present a user-selectablebutton that, when selected by a user, displays an illustration of whatthe finished product will look like. As non-limiting examples, the usermay see if the appearance of the rolled product is flat, or if it has anuneven wind, etc. In an exemplary wrapper process, the graphicalrepresentation may show how much overlap is present, how well the endsare sealed, how firm or loose the wrapper material is on the roll, etc.

Referring now to FIG. 13, an embodiment in which the machine emulatormodule 340 is linked to a process model 330 is depicted. The processmodel 330 may be configured to predict how inputted parameters mayaffect the overall process of the machine, and to detect potentialproblems with the process based on the inputted parameters (i.e.,transform input parameters into output messages indicative of theoverall process of the machine). For example, the process model 330 maygenerate a process output message 362 that indicates to the user thatparticular inputted parameters may cause a predicted process of themachine to operate in a manner that is harmful to the machine and/or themanufactured product. The process model 330 may be programmed torecognize problems based on inputted parameters. Regarding machineprocess issues, a message may be generated in response to a particularcombination of inputted parameters that indicates that the inputtedparameters may cause the elements of the machine to wear quickly suchthat the process may be adversely affected over time. Other processoutput messages may indicate that the particular inputted parameters maycause the machine to operate in a manner that is outside of protocol.Regarding product issues, the process model may be configured to detecthow inputted parameters may affect the overall process, and how theprocess may affect the finished product. For example, product model mayindicate that inputted parameters may cause known problems, such asconing, breaking at the incorrect perforation, tail control, etc. Theprocess model 330 may be programmed empirically, mathematically, or acombination of both.

As stated above with respect to the product model 320, the process model330 may receive the inputted parameters from the output response dataand/or desired product properties 342 (e.g., parameters corresponding toinput fields 101-106 illustrated in FIG. 4) of the emulator module 340.In this manner, a user may make changes to the desired productproperties provided to the emulator, and then predict how the desiredproduct properties will affect the process of the machine.

One specific, non-limiting example of a process model linked to anemulator module is the prediction or modeling of how a web materialbehaves based on different input parameters, such as input parameterscorresponding to different machine operations, mechanical elements,actuators, inertias, friction surfaces, and the like. The emulatormodule in conjunction with a process model may predict how stable theweb material is, and how reliable a particular process is, based onchanges in process and product parameters, particularly as the linespeed of the hybrid winder machine increases. This model may incorporateparameters and predict based on physics how stable the process will be,what speed limitations might be reached, etc. Such web handling modelingmay be utilized to develop better machine equipment. For example, in thehybrid winder context, better surface coatings for rollers may bedeveloped, how to add or modify air foils may be determined, how to bestchange the draws between rolls may be developed, etc.

The emulator module 340 may be linked to both the product model 320 andthe process model 330 simultaneously. The functionality of the productmodel 320, the process model 330, or both, may be integrated directlyinto the emulator module 340. In one embodiment, the emulator module340, the product model 320, and the process model 330 are all componentsof the machine (or human machine interface), and may be accessed throughthe human machine interface. A user may then be able to not only controlthe machine, but also run simulations and make output predictions usingthe emulator and product/process model functionality.

Linking the emulator module 340 with a product model 320 and a processmodel 330 may enable the emulator module 340 to determine how theproduct, process, and machine will behave based on user inputtedparameters (e.g., material properties, geometries, actuators, etc.) andindependently make conclusions about how a particular process will runor react. The emulator module 340 may utilize output response data frompast scenarios based on particular input parameters to predict idealinput parameters based on empirical modeling. In one embodiment, theemulator module 340 may have a smart mode that predicts parameter valuesbased on past experience, which may ideally provide the most reliableprocess for a given set of parameters.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be understood to those skilled inthe art that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method in a computer system for generatingpredicted product values of a product manufactured by a machine having aplurality of actuators and a plurality of mechanical elements, themachine being controlled by programmable logic control code, the methodcomprising the steps of: presenting a plurality of machine input fieldsrequesting a plurality of parameters associated with the plurality ofactuators and the plurality of mechanical elements; presenting aplurality of product input fields requesting a plurality of desiredproduct properties of the product; receiving one or more parameters fromthe plurality of machine input fields; receiving one or more desiredproduct properties from the plurality of product input fields;calculating output response data by an emulation of a mechanicaloperation of the machine using one or more parameters and the one ormore desired product properties, wherein the emulation simulates theprogrammable logic control code; providing at least a portion of theoutput response data to a product model wherein the product model is amathematical model configured to calculate one or more predicted productvalues based at least in part on the output response data provided tothe product model; and, presenting the one or more predicted productvalues.
 2. The method of claim 1 wherein the product model comprises amathematical model.
 3. The method of claim 2 wherein the mathematicalmodel is a MathCAD model or a MATLAB model.
 4. The method of claim 1wherein: the machine is a hybrid winder machine and the product is awound product of a web material; and, the predicted product valuescomprise a perforation strength value, a winding tension value, a rollcompressibility value, an embossed depth value, a roll diameter value,or combinations thereof.
 5. The method of claim 1 further comprising thestep of presenting a plurality of material input fields, wherein theplurality of material input fields corresponds to a plurality ofmaterial properties associated with the product.
 6. The method of claim1 further comprising the step of providing the one or more parametersand the one or more desired product properties to the product model,wherein the one or more predicted product values are based at least inpart on the output response data, the one or more parameters, and theone or more desired product properties.
 7. The method of claim 1 furthercomprising the steps of: presenting a plurality of material propertyinput fields, wherein the plurality of material property input fieldsare associated with a plurality of material properties of the product;and, receiving one or more material properties from the plurality ofmaterial input fields, wherein the output response data is based atleast in part on the one or more parameters, the one or more desiredproduct properties, and the one or more material properties.
 8. Themethod of claim 7 further comprising the step of providing the one ormore parameters, the one or more desired product properties, and the oneor more material properties to the product model, wherein the one ormore predicted product values are based at least in part on the outputresponse data, the one or more parameters, and the one or more desiredproduct properties.
 9. The method of claim 1 further comprising thesteps of: presenting a graphical representation of the output responsedata; and, presenting an animation of at least one predicted machineoperation based at least in part on the output response data.
 10. Amethod in a computer system for predicting a process of a machine havinga plurality of actuators and a plurality of mechanical elements, themachine being controlled by programmable logic control code andconfigured to fabricate a product, the method comprising the steps of:presenting a plurality of machine input fields requesting a plurality ofparameters associated with the plurality of actuators and the pluralityof mechanical elements; presenting a plurality of product input fieldsrequesting a plurality of desired product properties of the product;receiving one or more parameters from the plurality of machine inputfields; receiving one or more desired product properties from theplurality of product input fields; calculating, by a computer, outputresponse data by an emulation of a mechanical operation of the machineusing one or more parameters and the one or more desired productproperties, wherein the emulation simulates the programmable logiccontrol code; providing at least a portion of the output response datato a process model wherein the process model is a mathematical modelconfigured to generate one or more process output messages based atleast in part on the output response data provided to the process model,wherein the one or more process output messages correspond to apredicted process of the machine; and, presenting the one or moreprocess output messages.
 11. The method of claim 10 wherein the processmodel comprises a mathematical model.
 12. The method of claim 11 whereinthe mathematical model is a MathCAD model or a MATLAB model.
 13. Themethod of claim 10 wherein the one or more output messages indicate thatthe one or more parameters, the one or more desired product properties,or combinations thereof, cause a problem with the product.
 14. Themethod of claim 10 wherein the one or more output messages indicate thatthe one or more parameters, the one or more desired product properties,or combinations thereof, cause a predicted process of the machine tooperate outside of a protocol.
 15. The method of claim 10 furthercomprising the step of presenting a plurality of material property inputfields, wherein the plurality of material input fields corresponds to aplurality of material properties associated with the product.
 16. Themethod of claim 10 further comprising the step of providing the one ormore parameters and the one or more desired product properties to theprocess model, wherein the one or more output messages are based atleast in part on the output response data, the one or more parameters,and the one or more desired product properties.
 17. The method of claim10 further comprising the steps of: presenting a plurality of materialproperty input fields, wherein the plurality of material property inputfields are associated with a plurality of material properties of theproduct; and, receiving one or more material properties from theplurality of material property input fields, wherein the output responsedata is based at least in part on the one or more parameters, the one ormore desired product properties, and the one or more materialproperties.
 18. The method of claim 17 further comprising the step ofproviding the one or more parameters, the one or more desired productproperties, and the one or more material properties to the processmodel, wherein the one or more output messages are based at least inpart on the output response data, the one or more parameters, and theone or more desired product properties.
 19. The method of claim 10further comprising the steps of: presenting a graphical representationof the output response data; and, presenting an animation of at leastone predicted machine operation based at least in part on the outputresponse data.